Installation - HD Master

Installation instructions for the 2CN0002E BMS master.

We strongly recommend that you use prewired HD harnessed from Elithion.

If you choose instead to make your own harnesses, you must be able to do so with high quality assembly skills.
Unfortunately, we do not have the resources to teach all of our clients proper assembly procedures, which are essential for a successful project.
What we can do is to pass along this info to you:

• Proper crimping technique from Molex

This connector is for low power signals.

#	Name	Type	Function	Notes
1	GND	Gnd	Ground	Return for source current sensor
2	SRCCUR	Inputs	Source current	Analog input to measure current from the source / charger
3	5V	Pwr out	5 V supply	To power source current sensor
4	GND 6	Gnd	Bank ground	Return for TX and RX for bank 6; also for shield, do not terminate shield at far end
5	TX 6	Banks	Transmit out bank 6	To most positive cell in the bank; red wire
6	RX 6	Banks	Receive in bank 6	To most negative cell in the bank; white wire
7	GND 4	Gnd	Bank ground	Return for TX and RX for bank 4; also for shield, do not terminate shield at far end
8	TX 4	Banks	Transmit out bank 4	To most positive cell in the bank; red wire
9	RX 4	Banks	Receive in bank 4	To most negative cell in the bank; white wire
10	GND 2	Gnd	Bank ground	Return for TX and RX for bank 2; also for shield, do not terminate shield at far end
11	TX 2	Banks	Transmit out bank 2	To most positive cell in the bank; red wire
12	RX 2	Banks	Receive in bank 2	To most negative cell in the bank; white wire
13	GND 0	Gnd	Bank ground	Return for TX and RX for bank 0; also for shield, do not terminate shield at far end
14	TX 0	Banks	Transmit out bank 0	To most positive cell in the bank; red wire
15	RX 0	Banks	Receive in bank 0	To most negative cell in the bank; white wire
16	GND	Gnd	Signal ground	Use a separate wire from power ground, to avoid errors in analog readings.
17	CANL	CAN	CAN Bus low
18	TERM	CAN	CAN Bus termination
19	SOC	Lin out	State Of Charge analog out	Analog voltage: 5 V = 100 % full, down to 0 V = empty
20	DCL	Lin out	Discharge Current Limit	Analog voltage: 5 V = no limit, down to 0 V = no discharging current allowed.
21	GND	Gnd	Ground	Return for load current sensor
22	LODCUR	Inputs	Load current	Analog input to measure current to the load
23	5V	Pwr out	5 V supply	To power load current sensor
24	GND 7	Gnd	Bank ground	Return for TX and RX for bank 7; also for shield, do not terminate shield at far end
25	TX 7	Banks	Transmit out bank 7	To most positive cell in the bank; red wire
26	RX 7	Banks	Receive in bank 7	To most negative cell in the bank; white wire
27	GND 5	Gnd	Bank ground	Return for TX and RX for bank 5; also for shield, do not terminate shield at far end
28	TX 5	Banks	Transmit out bank 5	To most positive cell in the bank; red wire
29	RX 5	Banks	Receive in bank 5	To most negative cell in the bank; white wire
30	GND 3	Gnd	Bank ground	Return for TX and RX for bank 3; also for shield, do not terminate shield at far end
31	TX 3	Banks	Transmit out bank 3	To most positive cell in the bank; red wire
32	RX 3	Banks	Receive in bank 3	To most negative cell in the bank; white wire
33	GND 1	Gnd	Bank ground	Return for TX and RX for bank 1; also for shield, do not terminate shield at far end
34	TX 1	Banks	Transmit out bank 1	To most positive cell in the bank; red wire
35	RX 1	Banks	Receive in bank 1	To most negative cell in the bank; white wire
36	GND	Gnd	Signal ground	Use a separate wire from power ground, to avoid errors in analog readings.
37	CANH	CAN	CAN Bus high
38	TERM	CAN	CAN Bus termination
39	CGND	CAN	CAN Bus ground
40	CCL	Lin out	Charge Current Limit	Analog voltage: 5 V = no limit, down to 0 V = no charging current allowed.

This connector is for high power signals.

#	Name	Type	Function	Notes
1	FLT	O.D. out	Fault	Open collector, polarity selectable in software. Activated in case of fault.
2	K3	O.D. out	Negative contactor coil (-)	Open collector
3	K2	O.D. out	Positive contactor coil (-)	Open collector
4	K1	O.D. out	Precharge relay coil (-)	Open collector
5	FAN	O.D. out	Low power fan drive / drive for fan relay	Grounded when cooling is required
6	V+S	Pwr in	Power in from source	The BMS is powered by voltage at either terminal (uses isolating diodes). V+L must be powered whenever the load is on, and only then. V+S must be powered whenever the source is on, and only then. For example, in a BEV or PHEV application, V+L is powered by Ignition, V+S is powered whenever the vehicle is plugged into AC power. In a HEV application, V+S is powered by the ignition. In a UPS application, V+S is powered whenever there's AC power, and V+L is powered all the time. If only one power source is possible, use V+S. Which input powers the BMS selects which current sensor is used. If both are powered simultaneously, the current reading may double.
7	V+L	Pwr in	Power in from load
8	V+	Pwr out	Full voltage utility supply	Voltage present when BMS powered through either V+ line. May be used to power equipment such as loggers, remote controllers.
9	LLIM	O.D. out	Low Limit	Open collector, polarity selectable in software. Activated when the most discharged cell's voltage is too low
10	HLIM	O.D. out	High Limit	Open collector, polarity selectable in software. Activated when the most charged cell's voltage is too high.
11	PGND	Gnd	Power ground	Use a separate wire from signal ground, to avoid errors in analog readings.
12	FAN PWM	Dig out	Variable Duty Cycle Pulse Width Modulation	0% DC for no cooling, up to 100% DC for full cooling
13	PGND	Gnd	Power ground	Use a separate wire from signa ground, to avoid errors in analog readings.
14	Cont. Req.	Dig in	Contactor request	Requests that contactors be on. For vehicle applications, connected to the Ignition line (off when ignition goes off).
15	PGND	Gnd	Power ground	Use a separate wire from signal ground, to avoid errors in analog readings.
16	V+	Pwr out	Full voltage utility supply	Voltage present when BMS powered through either V+ line. May be used to power equipment such as loggers, remote controllers.

Use this circuit if driving contactors from the Lithiumate HD Master.

This controller has 2 separate grounds.

• Signal ground: low current, reference for digital and analog signals
• Power ground: carries the high current for power devices: fan driver and contactor coil drivers

Both of these grounds must be connected to the negative of the low voltage supply (the 12 V nominal power supply, DC-DC converter or battery that powers the BMS), each through a separate wire.
These grounds are connected to each other on the BMS controller by a small resistor.

The negative of the low voltage supply (which is connected to the signal and power grounds) may or may not be connected to the earth or chassis, as required by the application.

In general, for safety reasons, the negative of the high voltage battery (the Li-Ion pack that is managed by this BMS) should not be connected to these grounds. Yet, if safety is not an issue, as far as the Elithion BMS is concerned, it is OK to do so.

BOTH GROUND PINS MUST BE WIRED TO THE SUPPLY!

This controller has 2 separate power inputs

• Source: on when the power source is on, such as a battery charger
• Load: on when the battery load is on, such as a motor driver

The BMS is on when there's voltage on either of these inputs. See the specifications for the allowable voltage range and the supply currents.

The BMS provides 2 power outputs for external devices:

• V+: powered whenever either power input is powered, at the highest voltage of the two
• 5V: powered at the same time, but sourcing 5 V

See the specifications for the maximum current available from these outputs.

There are 7 Open Drain Outputs on the power connector

• FLT: Fault
• HLIM (High limit): battery unable to accept charge
• LLIM (Low limit): battery unable to accept discharge
• K1: precharge relay coil drive
• K2: positive contactor coil drive
• K3: negative contactor coil drive
• FAN: cooling fan drive

Each of these outputs is either open (clamped to 42 V) or connected to the power ground, depending on the state they are reporting.

• With a pull-up resistor to the 5 V supply, they can be used as TTL or CMOS logic outputs
• They can drive medium power DC loads directly, such as relays
• See the specifications for the maximum sinking current and maximum open circuit voltage for these outputs.

Note that the polarity (active open or active grounded) is programmable. See the programming instructions.

There are 3 linear (analog) outputs on the control connector

• SOC (State Of Charge)
• CCL (Charge Current Limit)
• DCL (Discharge Current Limit)

• These outputs produce a voltage in the range from 0 V to 5 V, according to the state of the condition they report
• They can drive light loads, such as the inputs of Analog to Digital converters
• They can drive resistors of no less than 5 kOhm, such as throttle pots
• See the specifications for their output resistance, and maximum voltage for these outputs.

There is one digital PWM output on the control connector

• PWM (Pulse Width Modulation)

• This is a CMOS output (0 or 5 V), with a high frequency square wave of variable duty cycle, from 0% (always at 0 V: no fan) to 100 % (always at 5 V: full fan speed)
• It can drive a light load, such as the inputs of a power buffer
• It cannot drive a fan directly

There are 3 signal inputs on the control connector

• Source Current: a linear (analog) input
• Load Current: a linear (analog) input
• Contactor request: a digital input

The control connector also has ground and 5 V outputs to power current sensors.

• The Source Current input can be driven by a charger that puts out a linear voltage proportional to the charging current
  • This input responds to voltages in the range from 0 V to 5 V, but it is protected against voltages outside this range
• The Contactor Request input can be driven by the 12 V ignition line in a vehicle

If the application includes a CAN bus, the CAN bus lines can be connected to it.

• The CAN bus is isolated (it is not referenced to the supply ground)
• Normally it is not necessary to connect the CAN ground
• If the master is at the end of the CAN bus, terminate the bus by connecting the each CAN line to one of the TERM lines.

Connect a USB mini-B cable to this port and to a computer running the Lithiumate GUI application.  

The battery pack should be divided into between 1 and 8 banks or at least 3 cells each.
A cell board is mounted on each cell.
The two end boards in each bank are connected to the control connector. The Master sends data to the cell boards ("TX") and receives back data ("RX").

Name	Type	Function	Wire color	Notes
TX	Out	Transmit out	Red	To most positive cell in the bank
GND	Gnd	TX return	Black
	Shield	Common for both TX and RX	-	Do not terminate at other end
	Gnd	RX return	Green	To most negative cell in the bank
RX	In	Receive in	White

 

If you wish to make your own harnesses, you may use the compoents and tools listed below.

Elithion PN	Description	Manuf & PN
EKV3416UA	16-way plug housing	JAE MX34016SF1
EKV3440UA	40-way plug housing	JAE MX34040SF1
EKV3403ST	22 AWG crimp socket	JAE M34S75C4F1
EKV3404ST	20 AWG crimp socket	JAE M34S75C4F2
n.a.	Hand crimping tool, 20 AWG	JAE CT150-1-MX34
n.a.	Hand crimping tool, 22 AWG	JAE CT150-2-MX34
n.a.	Extraction tool	JAE ET-MX34-1